Biomass high efficiency hydrothermal reformer

ABSTRACT

A mixing apparatus for producing a feedstock for a reformer, the mixing apparatus including at least one mixing vessel comprising a cylindrical vessel with a conical bottom; a steam inlet configured for introducing steam into the conical bottom; a carbonaceous material inlet configured for introducing a carbonaceous feed into the cylindrical vessel; and an outlet for a reformer feedstock comprising at least 0.3 pounds of steam per pound of carbonaceous material, with the at least one mixing vessel configured for operation at a pressure of greater than about 10 psig.

CROSS-REFERENCE TO RELATED APPLICATIONS

This application is a divisional application of U.S. patent applicationSer. No. 14/289,258, filed May 28, 2014, which is a divisionalapplication that claims the benefit under 35 U.S.C. § 121 of U.S. patentapplication Ser. No. 13/111,836, filed May 19, 2011, the disclosures ofwhich are hereby incorporated herein by reference in their entirety.

STATEMENT REGARDING FEDERALLY SPONSORED RESEARCH OR DEVELOPMENT

Not Applicable.

BACKGROUND

Field of the Invention

This disclosure relates generally to the conversion of carbonaceousfeedstock into synthesis gas. More specifically, this disclosure relatesto a reforming apparatus for the conversion of carbonaceous feedstock tosynthesis gas. Still more specifically, this disclosure relates to ahigh temperature, high efficiency reformer configured for production ofsynthesis gas from a reformer feedstock comprising at least onecarbonaceous material.

Background of the Invention

Processes for the production of synthesis gas from carbonaceousmaterials utilize gasification of a feedstock comprising thecarbonaceous materials in a so-called ‘reformer’ to produce a streamcomprising synthesis gas (i.e. hydrogen and carbon monoxide; also knownas syngas′). The product synthesis gas generally also comprises amountsof carbon dioxide and methane and may also comprise minor amounts ofother components. Generation of synthesis gas is disclosed in numerouspatents.

Synthesis gas produced via gasification of carbonaceous materials can beconverted into other compounds in a so-called Fischer-Tropsch reaction.Fischer-Tropsch (FT) synthesis can be used to catalytically producesynthetic liquid fuels, alcohols or other oxidized compounds. FTsynthesis occurs by the metal catalysis of an exothermic reaction ofsynthesis gas. Fischer-Tropsch (FT) technology can thus be utilized toconvert synthesis gas to valuable products. Hydrocarbon liquid productsof various Fischer-Tropsch processes are generally refined to produce arange of synthetic fuels, lubricants and waxes. Often, theFischer-Tropsch process is performed in a slurry bubble column reactor(SBCR). The technology of converting synthesis gas originating fromnatural gas into valuable primarily liquid hydrocarbon products isreferred to as Gas To Liquids (GTL) technology. When coal is the rawmaterial for the syngas, the technology is commonly referred to asCoal-To-Liquids (CTL). Fischer-Tropsch technology is one of severalconversion techniques included in the broader GTL/CTL technology.Desirably, the synthesis gas for subsequent production of valuableproducts via Fischer-Tropsch is produced from ‘green’ materials. Forexample, an environmentally-friendly system for the production ofsynthesis gas, which may subsequently be utilized to produceFischer-Tropsch products, would desirably allow for the production ofsynthesis gas from carbonaceous materials, such as biomass, which maygenerally be considered waste materials

The catalyst used in the reactor and to some extent the temperatures andpressures used, will determine what products can be obtained. SomeFischer-Tropsch processes are directed to the production of liquidhydrocarbons. Other Fischer-Tropsch processes are directed toward theproduction of alcohols. Depending on the subsequent downstreamapplication for which the synthesis gas is produced, the reformer can beoperated to provide synthesis gas having a desired molar ratio ofhydrogen to carbon monoxide.

Accordingly, there is a need in the art for systems and methods for theproduction of synthesis gas from carbonaceous materials. Such systemsand methods should preferably enable the environmentally-friendlyproduction of synthesis gas, for example by allowing the use ofsustainable and renewable feedstocks such as biomass, facilitatingsequestration of carbon dioxide and/or reducing the amount of wastematerial produced.

SUMMARY

Herein disclosed is a mixing apparatus for producing a feedstock for areformer, the mixing apparatus comprising: at least one mixing vesselcomprising: a cylindrical vessel with a conical bottom; a steam inletconfigured for introducing steam into the conical bottom; a carbonaceousmaterial inlet configured for introducing a carbonaceous feed into thecylindrical vessel; and an outlet for a reformer feedstock comprising atleast 0.3 pounds of steam per pound of carbonaceous material, with theat least one mixing vessel configured for operation at a pressure ofgreater than about 10 psig. In embodiments, the mixing apparatus furthercomprises one or more mixing vessel outlet lines fluidly connected withthe reformer via a distributor, whereby the reformer feedstock can beintroduced into a plurality of coiled tubes within the reformer.

In embodiments, the carbonaceous material inlet is located at or nearthe top of the cylindrical vessel. In embodiments, the at least onemixing vessel is configured for operation at a pressure of greater thanor equal to about 45 psig.

The mixing apparatus may further comprise one or more feed preparationapparatus upstream of the at least one mixing vessel. The one or morefeed preparation apparatus may comprise at least one component selectedfrom the group consisting of sizing apparatus configured to provide adesired size of carbonaceous material for the carbonaceous feed, anddrying apparatus configured to reduce the moisture content of acarbonaceous material for the carbonaceous feed. In embodiments, themixing apparatus comprises sizing apparatus configured to providecarbonaceous material having a desired size. The sizing apparatus may beoperable to provide carbonaceous material having a size in the range offrom about 0.001 cm to about 2.54 cm. In embodiments, the sizingapparatus comprises at least one grinder and at least one separatorconfigured to provide a carbonaceous material having an average particlediameter of less than about 3/16^(th) of an inch (0.47 cm). Inembodiments, the mixing apparatus comprises drying apparatus configuredto reduce the moisture content of a carbonaceous material for thecarbonaceous feed. The drying apparatus may comprise a dryer operable todry the carbonaceous material to a moisture content of less than orequal to about 20 weight percent.

In embodiments, the steam inlet is fluidly connected with a steamsuperheater operable to provide superheated steam. The steam superheatermay be fluidly connected with the reformer, whereby a flue gas producedin the reformer can be utilized to produce superheated steam in thesteam superheater. The reformer may be designed to produce the flue gasvia combustion of a fuel comprising Fischer-Tropsch tailgas.

In embodiments, the mixing apparatus further comprises a spent catalystrecycle line designed for introduction of spent catalyst/conversionproduct from a catalytic synthesis gas conversion process directly intothe at least one mixing vessel, the carbonaceous material inlet isfluidly connected with a spent catalyst recycle line designed forintroduction of spent catalyst/conversion product from a catalyticsynthesis gas conversion process, or both. The spent catalyst recycleline may be fluidly connected with a catalytic synthesis gas conversionapparatus configured to produce a product from synthesis gas produced inthe reformer. In embodiments, the catalytic synthesis gas conversionapparatus comprises at least one Fischer-Tropsch reactor. The at leastone Fischer-Tropsch reactor may contain an iron-based Fischer-Tropschcatalyst, and the spent catalyst/conversion product may comprise spentiron-based Fischer-Tropsch catalyst and Fischer-Tropsch hydrocarbons. Inembodiments, the catalytic synthesis gas conversion apparatus comprisesan alcohol synthesis reactor.

In embodiments, the outlet for the reformer feedstock is located at ornear a bottom of the at least one mixing vessel.

BRIEF DESCRIPTION OF THE DRAWINGS

For a more detailed description of the preferred embodiment of thepresent invention, reference will now be made to the accompanyingdrawings, wherein:

FIG. 1 is a schematic of a synthesis gas production system according toan embodiment of this disclosure, the production system or biorefinerycomprising a high efficiency, hydrothermal reformer and suitable forcarrying out the production of synthesis gas conversion products;

FIG. 2 is a schematic of a synthesis gas production system according toanother embodiment of this disclosure;

FIG. 3 is a schematic of a synthesis gas production system according toanother embodiment of this disclosure;

FIG. 4 is schematic of a feedstock handling and/or drying apparatusaccording to an embodiment of this disclosure; and

FIG. 5 is a flow diagram of a method of producing synthesis gasaccording to an embodiment of this disclosure.

NOTATION AND NOMENCLATURE

Certain terms are used throughout the following description and claimsto refer to particular system components. This document does not intendto distinguish between components that differ in name but not function.

As used herein, the term ‘carbonaceous feedstock’ includes not onlyorganic matter that is part of the stable carbon cycle, but alsofossilized organic matter such as coal, petroleum, and natural gas, andproducts, derivatives and byproducts thereof such as plastics, petroleumcoke and the like.

As used herein, the terms ‘hot’, ‘warm’, ‘cool’ and ‘cold’ are utilizedto refer to the relative condition of various streams. That is, a ‘hot’stream is at a higher temperature than a ‘warm’ stream, a ‘warm’ streamis likewise at a higher temperature than a ‘cool’ stream and a ‘cool’stream is likewise at a higher temperature than a ‘cold’ stream. Such astream may not ‘normally be considered as such. That is a ‘cool’ streammay have a temperature that is actually high enough to be considered hotor warm in conventional, non-relative usage.

As used herein the term ‘dry’ as applied to a carbonaceous feed materialis used to indicate that the feed material has a moisture contentsuitable for reforming, e.g. less than about 20 weight percent, and notto imply the complete absence of moisture.

DETAILED DESCRIPTION

I. Overview. Herein disclosed are a high temperature, high efficiency,biomass reformer, a mixing apparatus, a synthesis gas production systemcomprising same and a method of producing synthesis gas from at leastone carbonaceous material. The disclosed high temperature, highefficiency, reformer is configured for the production of synthesis gasfrom renewable and sustainable carbonaceous materials such as biomass.Accordingly, the disclosed bioreformer, the disclosed synthesis gasproduction system comprising the bioreformer and the disclosed processfor producing synthesis gas therewith represent clean technologies. Sucha reformer is significantly more environmentally-friendly thanconventional reformers that produce synthesis gas from other sources,such as from natural gas.

II. Synthesis gas production system. FIG. 1 is a schematic of asynthesis gas production system 100 according to this disclosure.Synthesis gas production system 100 comprises reformer 400 and mixingapparatus 300. As discussed further hereinbelow, synthesis gasproduction system 100 can further comprise feed handling and/or dryingapparatus 200, steam generation apparatus 500 or both. Each of thecomponent apparatus will be described in more detail hereinbelow.

High temperature, high efficiency biomass reformer 400. System 100comprises reforming apparatus 400, also referred to herein as biomassreformer 400. Description of reforming apparatus 400 will now be madewith reference to FIG. 2, which is a schematic of a synthesis gasproduction system 100A comprising mixing apparatus 300A, reformer 400Aand steam generation apparatus 500A, according to an embodiment of thisdisclosure and FIG. 3, which is a schematic of a synthesis gasproduction system 100B comprising mixing apparatus 300B, reformer 400Band steam generation apparatus 500B, according to another embodiment ofthis disclosure.

Reformer 400A is a high temperature, high efficiency reformer. Inembodiments, reformer 400 is a biomass reformer. Reformer 400A comprisesa plurality of coiled tubes 410A, 410B surrounded by enclosure,cylindrical vessel or firebox 407. In embodiments, biomass reformer 400Ais a cylindrical vessel. In embodiments, the cylindrical vessel 407 hasa height H1 in the range of from about 40 feet (12.2 m) to about 100feet (30.5 m), from about 50 feet (15.2 m) to about 100 feet (30.5 m),or from about 60 feet (18.3 m) to about 100 feet (30.5 m). Inembodiments, coiled tubes 410 have an inside diameter (ID) of at leastor about 2 inches (5.1 cm), at least or about 3 inches (7.6 cm), or atleast or about 4 inches (10.2 cm). Coiled tubes 410 may be configured ascylindrical helices and may be oriented vertically within cylindricalvessel 407. In embodiments, each of the coiled tubes 410 has a totallength or coil length that is at least 4, 5, 10, 15, 20 or 25 times thevertical height of the coiled tubes. In embodiments, each of the coiledtubes 410 has a total length in the range of from about 200 feet (61 m)to about 1000 feet (304.8 m), from about 400 feet (121.9 m) to about 800feet (243 m), or from about 400 feet (121.9 m) to about 700 feet (213.4m).

In embodiments, the metallurgy of the coiled tubes is upgraded such thatthe tubes are operable at the high temperatures of operation of a hightemperature reformer. A ‘high’ temperature reformer is operable at atemperature of at least 1093° C. (2000° F.). In embodiments, the coiledtubes are operable at temperatures up to 926° C. (1700° F.), 982° C.(1800° F.), 1038° C. (1900° F.), 1093° C. (2000° F.), 1149° C. (2100°F.) and a pressure of at least 2 psig (13.8 kPa), 5 psig (34.5 kPa), atleast 20 psig (137.9 kPa), greater than or about 40 psig (275.8 kPa) orabout 45 psig (310.3 kPa) or about 50 psig (344.7 kPa). In embodiments,the coiled tubes are fabricated from stainless steel, such as 310stainless steel. In embodiments, the coiled tubes are fabricated fromaustenitic nickel-chromium-based superalloys or other high temperaturealloys that are resistant to hydrogen attack and suitable for productionof coiled helices, such as INCONEL™. In embodiments, the coiled tubesare fabricated from INCONEL™ 800 HT. In embodiments, the coiled tubesare designed to provide at least 100,000 hours of operation.

As shown in FIG. 3, a distributor or flow divider 412 can be positionedexternal or internal to firebox 407 for distributing a reformerfeedstock comprising a mixture of cooled steam and dry carbonaceousmaterial to the plurality of coiled tubes 410. In embodiments,distributor 412 is positioned external to vessel 407. In embodiments,distributor 412 is configured to provide substantially equal amounts ofthe reformer feed mixture to each of the coiled tubes 410.

Distributor 412 distributes reformer feed mixture to each of theplurality of coiled tubes 410 (410A and 410B indicated in the embodimentof FIG. 3) via one or more reformer feed inlet lines 350 (350A and 350Bdepicted in the embodiment of FIG. 3). In embodiments, mixing apparatus300 (300A in FIG. 2; 300B in FIG. 3), further discussed hereinbelow,comprises a plurality of feed mixers 310 (mixers 310A and 310B depictedin FIG. 2; mixer 310C depicted in FIG. 3), the output of each of whichis fed via one or more reformer feed inlet lines 350 (350A and 350Bindicated in the embodiment of FIG. 2) into the coiled tubes 410.

The amount of superheated steam in the reformer feed mixture is afunction of the nature of the carbonaceous material (i.e. the feedstock)used. Steam provides the additional hydrogen necessary to produce, fromthe feedstock, suitable synthesis gas for subsequent production ofliquid hydrocarbons, alcohols and/or other oxidized compounds, or othersynthesis gas conversion products therefrom. In terms of thestoichiometric ratio of carbon to hydrogen in lower alcohols such asmethanol and ethanol and C⁵⁺ hydrocarbons, the dry feedstock may have astoichiometric excess of carbon relative to hydrogen. Thus water, eithertrapped in the feedstock or in the form of superheated steam, or both,can serve to provide additional hydrogen to maximize subsequentproduction of synthesis gas conversion products. In embodiments, priorto mixing, the feedstock is relatively dry, and sufficient water isprovided by combining superheated steam with the dried feedstockmaterial in mixing apparatus 300, as discussed hereinbelow.

In embodiments, from about 0.09 kilograms (0.2 pounds) to about 0.45kilograms (1 pound), from about 0.14 kg (0.3 pounds) to about 0.32 kg(0.7 pounds) or from about 0.14 kg (0.3 pounds) to about 0.27 kg (0.6pounds) of steam is added per pound of ‘dry’ feedstock comprising fromabout 4% to about 20% moisture, from about 9% to about 18% moisture orfrom about 12% to about 18% moisture, to provide the reformer feedmixture that is introduced into the coiled tubes of the reformer. Thereformer feed mixture can have a total water to feedstock ratio in therange of from about 0.2 to 1.0, from about 0.3 to about 0.7 or fromabout 0.3 to about 0.6.

Feedstock reformation carried out in the feedstock reformer isendothermic. Thus, reforming apparatus 400 comprises one or more burners404 operable to provide the necessary heat of the pyrolysis, reformingand/or gasification reaction(s) occurring within the coiled tubes 410 bycombusting fuel in the presence of oxygen.

Burners 404 are desirably positioned at or near the bottom of thereformer. Burners 404 may be positioned internal or external to firebox407. In embodiments, burner(s) 404 are internal to firebox 407. Theburner(s) 404 may be distributed substantially uniformly along thediameter of vessel 407. In embodiments, the reformer has from about 1 toabout 10 burners, from about 1 to about 4 burners, or from about 1 toabout 3 burners. Oxidant utilized by the burner(s) may be provided asair, enriched air, or substantially pure oxygen. For example, in theembodiment of FIG. 2, each of the burners 404 is provided with air viaone or more air inlet lines 405 and fuel provided via one or more fuelinlet lines 406. The oxidant and fuel may be fed separately to eachburner 404 or combined prior to entry thereto. The system can furthercomprise a forced draft (FD) fan 409 configured to provide air to an airpreheater 413 configured to raise the temperature of the inlet air froma first temperature (e.g. ambient temperature) to a temperature in therange of from about −18° C. (0° F.) to about 399° C. (750° F.), fromabout 38° C. (100° F.) to about 399° C. (750° F.) or from about 316° C.(600° F.) to about 399° C. (750° F.). In embodiments, flue gas exitingsteam generation apparatus 500A (discussed further hereinbelow) isutilized to heat the air upstream of burner(s) 404. The air may bepreheated by heat transfer with a flue gas stream in steam generatorflue gas outlet line(s) 570 exiting steam generator 501A. This flue gasmay have a temperature in the range of from about 649° C. (1200° F.) toabout 1260° C. (2300° F.), from about 760° C. (1400° F.) to about 1204°C. (2200° F.) or from about 871° C. (1600° F.) to about 1149° C. (2100°F.).

Fuel is provided to the one or more burners 404 via fuel inlet line(s)406. Any fuel known in the art can be utilized. In embodiments, the fuelprovided to the reformer is selected from the group consisting ofmethane (e.g. natural gas), synthesis gas (e.g. excess synthesis gas),tailgas (e.g. Fischer-Tropsch tailgas) and combinations thereof. Inembodiments, one or more of the burners 404 may be specially designedfor burning tailgas in line 770 or a mixture of tailgas with at leastone other gas such as methane or synthesis gas. The amount of aircombined with the fuel will be adjusted as known in the art based uponthe fuel utilized and the desired temperature within the reformer. Inembodiments, the reformer temperature is maintained at a temperature ofat least about 926° C. (1700° F.), 982° C. (1800° F.), 1038° C. (1900°F.), 1093° C. (2000° F.) or 1149° C. (2100° F.).

For greater energy independence of the overall system, excess synthesisgas can be made and used to run a turbine and generate electricity topower the compressors and other electrically driven devices.

The reformer comprises one or more reformer flue gas outlet lines 470for flue gas exiting the reformer. Desirably, reformer flue gas outletline(s) 470 is positioned at or near the top of the reformer. In theembodiment of FIG. 2, reformer flue gas outlet lines 470 are provided amanifold 408 fluidly connecting reformer 400A with steam generationapparatus 500A. The flue gas exiting reformer 400A can have atemperature in the range of at least 926° C. (1700° F.), 982° C. (1800°F.), 1038° C. (1900° F.), 1093° C. (2000° F.), 1149° C. (2100° F.). Thepressure of the flue gas can be in the range of from about −20 inchesH₂O to 0 inch H₂O; from about −16 inches H₂O to −2 inches H₂O; or fromabout −15 inches H₂O to −5 inches H₂O. In embodiments, the reformer isconfigured for operation at a pressure of greater than or equal to 5psig (34.5 kPa), 30 psig (206.8 kPa), 40 psig (275.8 kPa), 45 psig(310.3 kPa) or 50 psig (344.7 kPa). Operation of the reformer at higherpressures may allow a reduction in the number of compression stagesrequired upstream of a synthesis gas conversion apparatus and/or areduction in required compression horsepower.

Superheated steam from line(s) 550 carries the feedstock to thereformer. In the process of heating up the feedstock upon mixingtherewith, the steam may cool to a temperature in the range of fromabout 150° F. (66° C.) to about 1000° F. (538° C.), from about 200° F.(93° C.) to about 750° F. (399° C.), or from about 300° F. (149° C.) toabout 400° F. (204° C.). In the process of heating up the feedstock uponmixing therewith, the steam may cool to a temperature of approximately204° C. (400° F.) as the reformer feed mixture approaches the reformer.In embodiments, the inlet temperature of the reformer feed mixtureentering the reformer is at a temperature of about 204° C. (400° F.).The exit temperature of the synthesis gas leaving the reformer can be inthe range of from about 870° C. (1600° F.) to about 1205° C. (2200° F.)or from about 895° C. (1650° F.) to about 930° C. (1700° F.). Inembodiments, the reformer is operated at a pressure in the range of fromabout 34.5 kPa (5 psig) to about 275.8 kPa (40 psig).

Within the coiled tubes of the reformer, the carbonaceous materials inthe reformer feed are anaerobically reformed with superheated steam toproduce a product process gas comprising synthesis gas (hydrogen andcarbon monoxide). The process gas can further comprise other components,for example, methane, carbon dioxide, and etc. Minor amounts of otheringredients may be formed. The reformer can comprise an internal (see414B in FIG. 3) or external (see 414A in FIG. 2) manifold configured tocombine the process gas from each of the coiled tubes 410 into one ormore reformer process gas outlet lines 480. As indicated in theembodiment of FIG. 2, outlet lines 402 associated with each of thecoiled tubes can be combined via manifold 414A to provide process gas toreformer process gas outlet line 480. In embodiments, the reformer isconfigured to provide temperature, pressure and residence timeconditions suitable to provide a process gas comprising synthesis gashaving a desired molar ratio of H₂ to CO. In embodiments, the reformeris configured to provide a synthesis gas having a H₂:CO molar ratio inthe range of from about 0.7:1 to about 2:1, from about 0.7:1 to about1.5:1 or about 1:1. In embodiments, the reformer is configured toprovide a residence time within the reformer in the range of from about0.3 s to about 3 s, from about 0.3 s to about 2 s, from about 0.3 s toabout 1 s, or from about 0.4 s to about 0.6 s.

For any given feedstock, a desired composition of the resulting processgas (i.e. the proportions of hydrogen, carbon dioxide, carbon monoxideand methane) can be provided by adjusting the contact time in thereformer, the temperature at the reformer outlet, the amount of steamintroduced with the feed, and to a lesser extent, the reformer pressure.In embodiments, the synthesis gas is to be utilized downstream for theproduction of liquid hydrocarbons via Fischer-Tropsch conversion. Inembodiments, the synthesis gas is to be utilized downstream for theproduction of liquid hydrocarbons via Fischer-Tropsch conversion with aniron-based catalyst. In such embodiments, the system may be operatedwith a reformer exit temperature in the range of from about 898° C.(1650° F.) to about 926° C. (1700° F.) and a residence or contact timethat is in the range of from about 0.3 seconds to about 2.0 seconds inthe reformer. The contact or residence time can be calculated bydividing the internal volume of the reformer by the flow rate of theprocess gas exiting the reformer.

Mixing apparatus 300. As indicated in FIG. 1, the synthesis gasproduction apparatus of this disclosure further comprises mixingapparatus 300 upstream of reformer 400. Mixing apparatus 300 isconfigured to combine feedstock introduced thereto via feedstock inletline 250 with superheated steam introduced thereto via superheated steamline 550. As discussed further hereinbelow, the feedstock can beprovided via feedstock handling and/or drying apparatus 200 positionedupstream of mixing apparatus 300. As discussed further hereinbelow,superheated steam can be provided via steam generation apparatus 500configured to utilize the heat from the reformer flue gas and/or thereformer product gas to produce superheated steam from boiler feed water(BFW).

As depicted in the embodiment of FIG. 2, mixing apparatus 300A cancomprise one or more mixers 310 (two mixers, 310A and 310B, indicated inFIG. 2) configured to combine superheated steam with feedstock material.Feedstock can be introduced into the mixing apparatus via one or morefeedstock inlet lines 250. The feedstock comprises at least onecarbonaceous material. In embodiments, the feedstock comprises biomass.The feedstock can comprise, by way of non-limiting examples, lignite,coal, red cedar, southern pine, hardwoods such as oak, cedar, maple andash, bagasse, rice hulls, rice straw, weeds such as kennaf, sewersludge, motor oil, oil shale, creosote, pyrolysis oil such as from tirepyrolysis plants, used railroad ties, dried distiller grains, cornstalks and cobs, animal excrement, straw, or some combination thereof.The hydrogen and oxygen content for the various materials differ and,accordingly, operation of the system (e.g. amount of superheated steamcombined with the feedstock in the mixing apparatus, the reformertemperature and pressure, the reformer residence time) can be adjustedas known in the art to provide a process gas comprising synthesis gashaving a suitable molar ratio of H₂:CO for a desired subsequentsynthesis conversion application. The feedstock introduced into themixing apparatus can have an average particle size in the range of fromabout 0.006 inch (0.015 cm) to about 0.3 inch (0.8 cm), from about 0.01inch (0.025 cm) to about 0.25 inch (0.63 cm) or from about 0.1 inch(0.25 cm) to about 0.187 inch (0.5 cm). In embodiments, the feedstockintroduced into the mixing apparatus has an average particle size in therange of from about 3.9 E-5 inch (0.0001 cm) to about 1 inch (2.54 cm),from about 0.01 inch (0.0254 cm) to about 0.5 inch (1.27 cm) or fromabout 0.09 inch (0.24 cm) to about 0.2 inch (0.508 cm). In embodiments,the feedstock introduced into the mixing apparatus has an averageparticle size of less than about 0.01 inch (0.025 cm), less than about0.25 inch (0.63 cm) or less than about 3/16 inch (0.476 cm). Thefeedstock introduced into the mixing apparatus can have a moisturecontent in the range of from about 4 weight percent to about 20 weightpercent, from about 9 weight percent to about 18 weight percent, fromabout 5 weight percent to about 18 weight percent or from about 9 weightpercent to about 15 weight percent. As discussed further hereinbelow andmentioned hereinabove, a system of this disclosure can further comprise,upstream of the mixing apparatus and connected therewith via one or morelines 250, feedstock handling and/or drying apparatus 200.

Within the mixing apparatus 300, feedstock is combined with superheatedsteam to provide a reformer feed mixture. In the embodiment of FIG. 2,feedstock in line 250 is divided via lines 250A and 250B and introducedinto mixers 310A and 310B respectively. In embodiments, one or morespent catalyst recycle lines 755 is configured to directly or indirectlyrecycle at least a portion of a catalyst/conversion product (e.g.catalyst/wax or catalyst/alcohol) stream produced in a synthesis gasconversion apparatus to the reformer. Superheated steam, which may beproduced via steam generation apparatus 500 as further describedhereinbelow, is introduced via superheated steam lines 550, 550A and550B to mixing apparatus 300A. In embodiments, the mixing apparatus isconfigured to combine the feedstock in feedstock line 250 withsuperheated steam having a temperature in the range of from about 400°F. (204.4° C.) to about 1000° F. (537.8° C.), from about 600° F. (315.6°C.) to about 950° F. (510° C.) or from about 400° F. (204.4° C.) toabout 900° F. (482.2° C.) and/or a pressure in the range of from about150 psig (1034.2 kPa) to about 400 psig (2757.9 kPa), from about 200psig (1378.9 kPa) to about 375 psig (2585.5 kPa) or from about 250 psig(1723.7 kPa) to about 350 psig (2413.2 kPa). In embodiments, a system ofthis disclosure further comprises steam generation apparatus 500configured to provide superheated steam for introduction into mixingapparatus 300 as further described hereinbelow.

In the embodiment of FIG. 2, superheated steam is introduced into eachof the mixers 310A and 310B, respectively, via superheated steam lines550A and 550B. The reformer feed mixture comprising feedstock and steamis introduced into the reformer via one or more reformer inlet lines350. The feedstock/steam mixture from each mixer 310 may be introducedinto a coiled tube 410. For example, in the embodiment of FIG. 2,feedstock/steam exiting mixers 310A and 310B via lines 350A and 350B,respectively, are introduced into coiled tubes 410A and 410B,respectively. In the embodiment of FIG. 3, the feedstock/steam mixtureexiting mixing vessel 310C of system 100B is introduced via line 350,reformer feed distributor 412 and feed inlet lines 350A and 350B intocoiled tubes 410A and 410B, respectively. Other combinations of numberof mixers, manifolding of the outlets thereof, and distributors areenvisioned and not beyond the scope of this disclosure.

As indicated in FIG. 3, the mixing vessel 310C can be a cylindricalvessel having a conical bottom 320. In embodiments, superheated steam isintroduced at or near the bottom or into a conical section 320 at ornear the bottom of the mixer. Feedstock may be introduced, inembodiments, at or near the top of the mixer. In embodiments, themixture exits out the bottom of the mixing vessel.

In embodiments, the mixing vessel(s) (310A/310B/310C) are pressurevessels configured for operation at a pressure in the range of fromabout 5 psig (34.5 kPa) to about 50 psig (344.7 kPa), from about 30 psig(206.8 kPa) to about 50 psig (344.7 kPa), from about 45 psig (310.3 kPa)to about 50 psig (344.7 kPa), or configured for operation at or greaterthan about 30 psig (206.8 kPa), 45 psig (310.3 kPa) or 50 psig (344.7kPa). In embodiments, the mixing vessels are configured for operation ata temperature in the range of from about 150° F. (66° C.) to about 1000°F. (538° C.), from about 200° F. (93° C.) to about 750° F. (399° C.), orfrom about 300° F. (149° C.) to about 400° F. (204° C.).

The mixing apparatus may be configured to provide a reformer feedmixture by combining from about 0.3 pound of steam per pound offeedstock to about 0.4, 0.5, 0.6, 0.7, 0.8, 0.9 or 1 pound ofsuperheated steam per pound of feedstock. In embodiments, the mixingapparatus is configured to provide a reformer feed mixture by combiningless than or equal to about 1, 0.9, 0.8, 0.7, 0.6, 0.5 or less than orequal to about 0.4 pound of superheated steam per pound of feedstock.

As indicated in FIG. 3 and discussed further hereinbelow, a portion ofthe saturated steam exiting the steam generator via one or more steamgenerator steam outlet line(s) 560 can be sent via one or more line(s)560A and 560C to an excess steam condenser 516. Condensate from excesssteam condenser 516 can be combined with condensate from elsewhere inthe system (for example, with condensate in condensate outlet line 282from a dryer air preheater of feed handling and/or drying apparatus 200,as discussed further hereinbelow). Condensate can be collected fordisposal and/or recycle and reuse via line 283.

Steam generation apparatus 500. The synthesis gas production systemdisclosed herein may further comprise steam generation apparatus 500configured to provide superheated steam for reforming feedstock withinreformer 400/400A/400B. As depicted in the embodiment of FIG. 1, water(e.g. boiler feed water or BFW) is introduced into steam generationapparatus 500 via one or more BFW inlet lines 580, ‘hot’ reformer fluegas is introduced into steam generation apparatus 500 via one or morereformer flue gas outlet lines 470, ‘hot’ product process gas isintroduced into steam generation apparatus 500 via one or more reformerprocess gas outlet lines 480, superheated steam exits steam generationapparatus 500 via one or more superheated steam outlet lines 550,saturated steam exits steam generation apparatus 500 via one or moresteam generator steam outlet lines 560, ‘cool’ flue gas exits steamgeneration apparatus 500 via one or more steam generator flue gas outletlines 570 and ‘cool’ process gas exits steam generation apparatus 500via one or more steam generator process gas outlet lines 450.

Description of a suitable steam generation apparatus will now be madewith reference to FIG. 2. In the embodiment of FIG. 2, steam generationapparatus 500A comprises reformer flue gas and reformer effluent steamgenerator 501A and steam superheater 501B. Reformer flue gas andreformer effluent steam generator 501A is configured to producesaturated steam by heat transfer from the ‘hot’ reformer effluentprocess gas and the ‘warm’ reformer flue gas exiting steam superheater501B. Reformer effluent process gas is introduced into reformer flue gasand reformer effluent steam generator 501A via reformer process gasoutlet line(s) 480. The ‘hot’ process gas introduced into reformer fluegas and reformer effluent steam generator 501A via reformer process gasoutlet line(s) 480 may have a temperature in the range of from about870° C. (1600° F.) to about 1205° C. (2200° F.) or from about 895° C.(1650° F.) to about 930° C. (1700° F.). In embodiments, the ‘hot’process gas has a pressure in the range of from about 34.5 kPa (5 psig)to about 275 KPa (40 psig). Within reformer flue gas and reformereffluent steam generator 501A, steam is commonly generated from the fluegas and the process gas, although the two gases are not mixed. ‘Cool’reformer process gas leaves reformer flue gas and reformer effluentsteam generator 501A via steam generator process gas outlet line(s) 450.The ‘cool’ process gas exiting reformer flue gas and reformer effluentsteam generator 501A via steam generator process gas line(s) 450 mayhave a temperature in the range of from about 400° C. (752° F.) to about800° C. (1472° F.), from about 400° C. (752° F.) to about 600° C. (1112°F.) or about 400° C. (752° F.) and/or a pressure in the range of fromabout 5 psig (34.5 kPa) to about 50 psig (344.7 kPa), from about 10 psig(68.9 kPa) to about 40 psig (275.8 kPa) or from about 20 psig (137.9kPa) to about 30 psig (206.8 kPa).

Reformer flue gas is introduced into reformer flue gas and reformereffluent steam generator 501A via reformer flue gas outlet line(s) 470.The ‘hot’ flue gas introduced into reformer flue gas and reformereffluent steam generator 501A via reformer flue gas outlet line(s) 470may have a temperature in the range of from about 530° F. (276.7° C.) toabout 1500° F. (815.6° C.), from about 530° F. (276.7° C.) to about1200° F. (648.9° C.) or about 530° F. (276.7° C.) and/or a pressure inthe range of from about −20 inches H₂O to 0 inches H₂O; from about −15inches H₂O to about −5 inches H₂O; or from about −10 inches H₂O to about−5 inches H₂O. As depicted in FIG. 2, in embodiments the reformer fluegas passes through steam superheater 501B, as discussed furtherhereinbelow, prior to introduction into reformer flue gas and reformereffluent steam generator 501A. In such instances, the ‘warm’ flue gasintroduced into the reformer flue gas and reformer effluent steamgenerator 501A may have a temperature in the range of from about 1350°F. (732.2° C.) to about 2050° F. (1121.1° C.), from about 1450° F.(787.8° C.) to about 1950° F. (1065.6° C.) or from about 1350° F.(732.2° C.) to about 1850° F. (1010° C.) and/or a pressure in the rangeof from about −20 inches H₂O to 0 inch H₂O; −16 inches H₂O to −5 inchesH₂O; −15 inches H₂O to 5 inches H₂O. In embodiments, the temperature ofthe ‘warm’ flue gas is about 150 degrees less than that of the ‘hot’flue gas, i.e. the flue gas temperature drop across steam superheater501B is in the range of from about 130-170 degrees, from about 140-160degrees, or about 150 degrees.

‘Cool’ reformer flue gas leaves reformer flue gas and reformer effluentsteam generator 501A via steam generator flue gas outlet line(s) 570.The ‘cool’ flue gas exiting reformer flue gas and reformer effluentsteam generator 501A via steam generator flue gas outlet line(s) 570 mayhave a temperature in the range of from about 50° F. (10° C.) to about400° F. (204.4° C.), from about 200° F. (93.3° C.) to about 400° F.(204.4° C.) or about 400° F. (204.4° C.) and/or a pressure in the rangeof from about −20 inches H₂O to about 20 inches H₂O; from about −16inches to about 20 inches H₂O; or from about −15 inches H₂O to about −10inches H₂O. Induced draft (ID) fan 573 can serve to draw ‘cool’ reformerflue gas exiting reformer flue gas and reformer effluent steam generator501A via steam generator flue gas outlet line(s) 570 through airpreheater 413, discussed hereinabove. Heat transfer to the air withinair preheater 413 may provide a ‘cold’ flue gas for use elsewhere in thesystem, for example in a dryer air heater of a feed handling and/ordrying apparatus 200, as further discussed hereinbelow. The ‘cold’ fluegas passing out of air preheater 413 in line(s) 570 may have atemperature in the range of from about −18° C. (0° F.) to about 399° C.(750° F.), from about 38° C. (100° F.) to about 399° C. (750° F.) orfrom about 316° C. (600° F.) to about 399° C. (750° F.) and/or apressure in the range of from about −20 inches H₂O to about 20 inchesH₂O; from about −16 inches to about 20 inches H₂O; or from about −15inches H₂O to about −10 inches H₂O.

One or more steam generator steam outlet lines 560 carries steam (e.g.saturated steam) from reformer flue gas and reformer effluent steamgenerator 501A. A portion of the saturated steam may be directed via oneor more steam export lines 560A for export to another apparatus or useelsewhere in the system. As indicated in the embodiment of FIG. 2, allor a portion of the saturated steam produced in reformer flue gas andreformer effluent steam generator 501A can be directed to steamsuperheater 501B configured to produce superheated steam. Steamsuperheater 501B is configured to provide superheated steam at atemperature in the range of from about 400° F. (204.4° C.) to about1000° F. (537.8° C.), from about 600° F. (315.6° C.) to about 950° F.(510° C.) or from about 400° F. (204.4° C.) to about 900° F. (482.2° C.)and/or a pressure in the range of from about 150 psig (1034.2 kPa) toabout 400 psig (2757.9 kPa), from about 200 psig (1379 kPa) to about 375psig (2585.5 kPa) or from about 250 psig (1723.7 kPa) to about 350 psig(2413.2 kPa). In embodiments, steam superheater 501B operates via heattransfer from the ‘hot’ reformer flue gas in reformer flue gas outletline(s) 470. Steam superheater 501B may be configured on a manifold orheader 408 comprising reformer flue gas outlet(s) 470. As mentionedhereinabove, the ‘warm’ flue gas exiting the steam superheater may havea temperature in the range of from about 1500° F. (815.6° C.) to about2200° F. (1204.4° C.), from about 1600° F. (871.1° C.) to about 2150° F.(1176.7° C.) or from about 1600° F. (871.1° C.) to about 2100° F.(1148.9° C.) and/or a pressure in the range of from about −20 inches H₂Oto 0 inches H₂O; −16 inches H₂O to −5 inches H₂O; −15 inches H₂O to 5inches H₂O. As discussed hereinabove, superheated steam exiting steamsuperheater 501B can be introduced into the mixing apparatus 300 via oneor more superheated steam lines 550.

Reformer flue gas and reformer effluent steam generator 501A may, asknown in the art, be associated with one or more blowdown drums 515configured to purge water off and control the solids level withinreformer flue gas and reformer effluent steam generator 501A.

Description of a suitable steam generation apparatus according toanother embodiment of this disclosure will now be made with reference toFIG. 3. In the embodiment of FIG. 3, the steam generation apparatus 500Bcomprises flue gas steam generator 501A″ and reformer effluent steamgenerator 501A′. In the embodiment of FIG. 3, ‘hot’ reformer effluentprocess gas exiting reformer 400B via reformer process gas outlet lines480 passes through reformer effluent steam generator 501A′, configuredfor transfer of heat from the ‘hot’ reformer process gas to BFWintroduced thereto via BFW inlet line 580. ‘Cool’ process gas exitingreformer effluent steam generator 501A′ via steam generator process gasoutlet line 450 may have a temperature in the range of from about 752°F. (400° C.) to about 1472° F. (800° C.), from about 752° F. (400° C.)to about 1112° F. (600° C.) or about 752° F. (400° C.) and/or a pressurein the range of from about 5 psig (34.5 kPa) to about 50 psig (344.7kPa), from about 10 psig (68.9 kPa) to about 40 psig (275.8 kPa) or fromabout 20 psig (137.9 kPa) to about 30 psig (206.8 kPa).

Reformer flue gas outlet line(s) 470 may fluidly connect reformer 400Bwith steam superheater 501B′. As discussed in regard to FIG. 2, steamsuperheater 501B′ is configured to produce superheated steam having atemperature in the range of from about 400° F. (204.4° C.) to about1000° F. (537.8° C.), from about 600° F. (315.6° C.) to about 950° F.(510° C.) or from about 900° F. (482.2° C.) and/or a pressure in therange of from about 150 psig (1034.2 kPa) to about 400 psig (2757.9kPa), from about 200 psig (1379 kPa) to about 375 psig (2585.5 kPa) orfrom about 250 psig (1723.7 kPa) to about 350 psig (2413.2 kPa). One ormore superheated steam lines 550 are configured to carry the superheatedsteam from steam superheater 501B′ to mixing vessel(s) 310C. The ‘warm’flue gas exiting steam superheater 501B′ has a temperature in the rangeof from about 1350° F. (732.2° C.) to about 2050° F. (1121.1° C.), fromabout 1450° F. (787.8° C.) to about 1950° F. (1065.6° C.) or about 1850°F. (1010° C.) and/or a pressure in the range of from about −20 inchesH₂O to 0 inch H₂O; −16 inches H₂O to −5 inches H₂O; −15 inches H₂O to 5inches H₂O and passes through flue gas steam generator 501A″, configuredfor transferring heat from the ‘warm’ reformer flue gas to the steam inline 580A. One or more lines 560 are configured to carry saturated steamexiting flue gas steam generator 501A″.

One or more steam generator flue gas outlet lines 570 are configured tocarry ‘cool’ flue gas from flue gas steam generator 501A″. As mentionedhereinabove, the ‘cool’ flue gas exiting flue gas steam generator 501A″can have a temperature in the range of from about 50° F. (10° C.) toabout 400° F. (204.4° C.), from about 200° F. (93.3° C.) to about 400°F. (204.4° C.) or about 400° F. (204.4° C.) and/or a pressure in therange of from about −20 inches H₂O to about 20 inches H₂O; from about−16 inches to about 20 inches H₂O; or from about −15 inches H₂O to about−10 inches H₂O. As discussed with regard to FIG. 2, the ‘cool’ flue gasin steam generator flue gas outlet line 570 may be used to heatcombustion air in combustion air preheater 413. Combustion air preheater413 may be configured to heat air introduced thereto via FD fan 406 andone or more air inlet lines 405 from a first lower temperature (e.g.ambient temperature) to a second higher temperature in the range of fromabout 38° C. (100° F.) to about 399° C. (750° F.), from about 316° C.(600° F.) to about 399° C. (750° F.) or about 399° C. (750° F.) forintroduction into the reformer burner(s). ‘Cold’ flue gas exiting airpreheater 413 may have a temperature in the range of from about −18° C.(0° F.) to about 399° C. (750° F.), from about 38° C. (100° F.) to about399° C. (750° F.) or from about 316° C. (600° F.) to about 399° C. (750°F.) and/or a pressure in the range of from about −20 inches H₂O to about20 inches H₂O; from about −16 inches to about 20 inches H₂O; or fromabout −15 inches H₂O to about −10 inches H₂O. The ‘cold’ flue gas may beutilized elsewhere in the refinery, for example, in a dryer air heaterof a feed handling and/or drying apparatus, as further discussedhereinbelow.

It will be apparent to those of skill in the art that flue gas steamgenerator 501A″ and reformer effluent steam generator 501A′ of theembodiment of FIG. 3 may be combined within a single vessel as indicatedin the embodiment of FIG. 2.

Feed handling and drying apparatus 200. A system of this disclosure mayfurther comprise feed handling and/or drying apparatus configured toprovide feed material of a desired average particle size, compositionand/or moisture content to the downstream mixing apparatus. Inembodiments, the feed handling and/or drying apparatus is substantiallyas disclosed in U.S. Pat. No. 7,375,142, the disclosure of which ishereby incorporated herein in its entirety for all purposes not contraryto this disclosure.

Suitable feed handling and/or drying apparatus can comprise an unloadingand tramp metal removal zone I, a comminuting zone II, a drying zoneIII, a reformer feed hopper zone IV, or some combination of two or morethereof. A feed handling and/or drying apparatus will now be describedwith reference to FIG. 4, which is a schematic of a feeding and dryingapparatus 200A according to an embodiment of this disclosure. Feedhandling and/or drying apparatus 200A comprises unloading and trampmetal removal zone I configured for unloading of feed material andremoval of undesirables therefrom. Unloading and tramp removal zone Ican comprise a truck unloading hopper 205 into which delivered feedmaterial is deposited. Truck unloading hopper 205 may be associated witha tramp metal detector 204 configured to determine the presence orabsence of undesirables such as metals in the feed material. Unloadingand tramp removal zone I can further comprise a conveyor 203 configuredto convey feed material onto a weigh belt feeder 206. A tramp metalseparator 207 is configured to remove tramp metal and other undesirablesfrom the feed material introduced thereto. Removed undesirables can beintroduced via line 208 into and stored in a bin 209 for disposal.

Comminuting zone II can be positioned downstream of unloading and trampremoval zone I, as indicated in FIG. 4, or can be downstream of anunloading zone (i.e. in the absence of a tramp removal zone).Comminuting zone II comprises apparatus configured to comminute the feedmaterial. In embodiments, the comminuting zone comprises at least onegrinder 210. A comminuting zone II may be used depending on theconsistency of the feedstock. In embodiments, the feedstock is primarilywood and/or other organic material. Grinder 210 may be used if thefeedstock is clumped together, in unusually large conglomerates, or ifthe feedstock needs to be further ground before being dried. After thefeedstock is optionally subjected to grinding, the ground material maybe passed via grinder outlet line 212 into one or more grinder dischargecyclones 220 configured to separate a larger average size fraction offeed material from a smaller sized fraction. The larger sized fractionmay be introduced via one or more grinder discharge cyclone outlet lines225 into one or more dryers 260 of dryer zone III configured to reducethe moisture content of the material fed thereto. The smaller sizedfraction from grinder discharge cyclone 220 may be passed via grinderdischarge fines outlet line 222 and grinder discharge blower 230 into adryer baghouse 240 of drying zone III, as further discussed hereinbelow.Drying zone III comprises at least one dryer 260 configured to reducethe moisture content of feed material introduced therein. In theembodiment of FIG. 4, drying zone III comprises dryer 260, dryer airheater 280, dryer cyclone 265, dryer baghouse 240, accumulator 245,dryer exhaust fan 241 and dryer stack 246. Various embodiments maycomprise any combination of these components. Within drying zone III,the feedstock is dried to a moisture content in the range of from about4% to about 20%, from about 5% to about 15% or from about 9% to about15%. The flue gas and air fed into dryer 260 mixes with comminutedfeedstock to dry it, purge it and heat it for further processing.

An air supply fan 261 is configured to introduce air via line 262 andreformer flue gas (e.g. ‘cold’ reformer flue gas from air preheater 413)via line 570 into dryer air heater 280. The flue gas may be addedupstream of dryer air preheater 280 to prevent above 400° F. (204.4° C.)to the inlet of dryer 260, preventing fire therein. As mentionedhereinabove, the ‘cold’ flue gas may have a temperature in the range offrom about −18° C. (0° F.) to about 399° C. (750° F.), from about 38° C.(100° F.) to about 399° C. (750° F.) or from about 316° C. (600° F.) toabout 399° C. (750° F.) and/or a pressure in the range of from about −20inches H₂O to about 20 inches H₂O; from about −16 inches to about 20inches H₂O; or from about −15 inches H₂O to about −10 inches H₂O. Inembodiments, the flue gas introduced via line 570 comprises about 80%nitrogen and 20% CO₂.

A portion of the effluent steam from reformer effluent and reformer fluegas steam generator 501A or from flue gas steam generator 501A″ can beintroduced via line 560A or 560D into dryer air preheater 280. The steamintroduced into dryer air preheater 280 may have a temperature in therange of from about 150° F. (65.6° C.) to about 500° F. (260° C.), fromabout 250° F. (121.1° C.) to about 450° F. (232.2° C.) or from about300° F. (148.9° C.) to about 400° F. (204.4° C.) and/or a pressure inthe range of from about 70 psig (482.6 kPa) to about 300 psig (2068.4kPa), from about 150 psig (1034.2 kPa) to about 300 psig (2068.4 kPa) orfrom about 250 psig (1723.7 kPa) to about 300 psig (2068.4 kPa).Condensate outlet line 282 is configured for removal of condensate fromair dryer 280. The pressure of the condensate may be reduced downstreamof the air dryer 280 and the condensate combined as indicated in FIG. 3with condensate from excess steam condenser 516. Heated air exitingdryer air heater 280 via heated air line 284 may have a temperature inthe range of from about −18° C. (0° F.) to about 204° C. (400° F.), fromabout −18° C. (0° F.) to about 149° C. (300° F.) or from about −18° C.(0° F.) to about 93.3° C. (200° F.). Desirably, the heated airtemperature does not exceed 400° F.

Heated air line 284 fluidly connects dryer air heater 280 with dryer260. Drying zone III may further comprise a heated air distributor 286configured to divide heated air line 284 into a plurality of heated airdryer inlet lines. For example, in the embodiment of FIG. 4, distributor286 divides the flow of air from heated air line 284 into three heatedair dryer inlet lines 284A-284C. Air passing through dryer 260 maycomprise entrained feed material. Accordingly, drying zone III cancomprise one or more dryer cyclones 265 configured to separate solidsfrom the air exiting dryer 260. In the embodiment of FIG. 4, air exitingdryer 260 via dryer vent lines 286A-286C is combined via air manifold287 into dryer vent line 281 which is fed into dryer cyclone 265. It isto be noted that, although three air inlet and air outlet (vent) linesare shown in the embodiment of FIG. 4, any number of air inlet lines andoutlet lines may be utilized. Additionally, the number of air inletlines to dryer 260 need not be equal to the number of air outlet or ventlines.

Dryer cyclone 265 is configured to remove solids from the vent gasexiting dryer 260. Air and any fines entrained therein exit dryercyclone 265 via dryer cyclone fines outlet line 266, while solids exitdryer cyclone 265 via dryer cyclone solids outlet line 267. Line 267 maybe fluidly connected with reformer feed hopper inlet line 276. Dryercyclone fines outlet line 266 may be configured to introduce air andentrained fines into dryer baghouse 240 along with fines introducedthereto from grinder discharge cyclone 220, grinder discharge cycloneoutlet line 222, grinder discharge blower 230 and/or grinder dischargeblower outlet line 231. In embodiments, dryer cyclone 265 is configuredto provide solids having a particle size of greater than 3/32″ (2.5 mm)or greater than 3/16″ (4.8 mm) into dryer cyclone solids outlet line267. In embodiments, dryer cyclone 265 is configured to separate solidshaving a particle size of less than 3/16″ into dryer cyclone finesoutlet line 266. In embodiments, dryer cyclone 265 has an efficiency ofat least 85, 90, 92, 95, 96, 97, or 98 percent.

One or more dryer baghouses 240 are configured to remove solids from theair introduced thereto. One or more dryer baghouse solids outlet lines243 are configured to introduce solids separated within dryer baghouse240 into reformer feed hopper cyclone inlet line 276 of reformer feedhopper zone IV, further discussed hereinbelow. In embodiments, dryerbaghouse 240 is configured to provide solids having a particle size ofgreater than 20, 15, 10 or 5 μm into dryer baghouse solids outlet line243. In embodiments, dryer baghouse 240 is configured to separate solidshaving a particle size of less than 10 um into dryer baghouse finesoutlet line 244.

One or more dryer baghouse fines outlet lines 244 are configured tointroduce gas from dryer baghouse 240 into dryer stack 246, optionallyvia dryer exhaust fan 241 and line 247. A line 251 may introduce airinto an accumulator 245 prior to introduction into dryer baghouse(s)240.

Feed handling and/or drying apparatus 200A can further comprise areformer feed hopper zone IV. The reformer feed hopper zone IV comprisesat least one reformer feed hopper and a feeder configured for feedingfeed material into mixing apparatus 300. In the embodiment of FIG. 4,reformer feed hopper zone IV comprises reformer feed hopper 295 andmixing vessel rotary feeder 297. Reformer feed hopper zone IV canfurther comprise a surge hopper 270, a reformer feed hopper blower 275and a reformer feed hopper cyclone 290, as indicated in the embodimentof FIG. 4. One or more dried feed lines 294 are configured to introducedried feed material from one or more dryers 260 of dryer zone III intoreformer feed hopper zone IV. The feed material may be introduced into asurge hopper 270, configured for storage of surplus dried feed materialand supply therefrom to reformer feed hopper 295. A reformer feed hopperblower 275 may be incorporated into zone IV for pushing dried feedmaterial and/or separated solids introduced into reformer feed hoppercyclone inlet line 276 from dryer(s) 260 and/or surge hopper(s) 270 vialine(s) 271, from dryer cyclone(s) 265 via dryer cyclone solids outletline(s) 267, from dryer baghouse(s) 240 via dryer baghouse solids outletline(s) 243 into reformer feed hopper cyclone(s) 290. In alternativeembodiments, the material in reformer feed hopper inlet line(s) 276 isintroduced directly into reformer feed hopper 295. Reformer feed hoppercyclone 290 is configured to separate fines from material introducedtherein. In embodiments, a reformer feed hopper cyclone outlet line 292is configured to introduce fines separated within reformer feed hoppercyclone 290 into dryer baghouse 240, optionally via grinder dischargeblower outlet line 231 as indicated in the embodiment of FIG. 4. Inembodiments, reformer feed hopper cyclone 290 is configured to providesolids having an average particle size in the range of from about 3.9E-5 inch (0.0001 cm) to about 1 inch (2.54 cm), from about 0.01 inch(0.0254 cm) to about 0.5 inch (1.27 cm) or from about 0.09 inch (0.24cm) to about 0.2 inch (0.51 cm) into reformer feed hopper 295. Inembodiments, the feed material in reformer feed hopper 295 is of a sizeallowing it to pass through a 4.8 millimeter ( 3/16 inch) screen. Inembodiments, reformer feed hopper cyclone 290 is configured to separatesolids having a particle size of less than 3/16″ (0.48 cm) into reformerfeed hopper cyclone fines outlet line 292. Feed material is introducedinto reformer feed hopper 295 via reformer feed hopper inlet line 276and optionally reformer feed hopper cyclone 290. In embodiments,reformer feed hopper 295 is a cylindrical vessel having a conicalbottom. In embodiments, reformer feed hopper cyclone 295 provides anefficiency of at least 80, 85, 90, 92, 95, 96, 97 or 98 percent.

Mixing vessel rotary feeder 297 is configured to introduce feed materialfrom reformer feed hopper 295 into mixing apparatus 300. As needed, feedmaterial is fed from reformer feed hopper 295 and rotary feeder 297 intomixing apparatus 300. Rotary feeder 297 may be substantially asdescribed in U.S. Pat. No. 7,375,142. Feed material exits reformer feedhopper 295 via feed hopper outlet line 296, which fluidly connectsreformer feed hopper 295 with mixing vessel rotary feeder 297.

In embodiments, one or more purge lines 291 is configured to introducepurge gas (e.g. flue gas or plant air) for purge into and push feedmaterial through reformer feed hopper 295. In embodiments, the purge gasis flue gas comprising about 80% nitrogen and about 20% carbon dioxide,helping to insure that the reformation process in reformer 400 will becarried out anaerobically. Reformer feed hopper 295 may also include avent for venting flue gas. From reformer feed hopper 295, feedstocksettles into feed hopper outlet line(s) 296, which extends from thebottom of reformer feed hopper 295. The feedstock is metered by rotaryvalve 297 into feedstock inlet line 250, along which it is entrainedwith steam under pressure entering from superheated steam line 550 ofmixing apparatus 300. To keep feedstock flowing into the stream ofsteam, and in order to counter steam back pressure in line 250, a supplyof gas is moved through rotary feeder purge gas inlet line 288 via acompressor to an inlet just below valve 297. To prevent the pressure infeedstock inlet line 250 from blowing feedstock back into rotary valve297, some of the gas is also split off from rotary feeder purge gasinlet line 288 and fed to an inlet of mixing vessel rotary feeder 297.Rotary feeder 297 includes a central rotor having a plurality of vaneswhich divide the interior of valve 297 into separate compartments.Opposite the inlet on rotary valve 297, is an outlet pressure vent line289. As the rotor of valve 297 rotates, the compartment formed by thevanes at the top fill with feedstock. That filled compartment is thenrotated until it opens to the inlet, where it is pressurized withincoming gas. As the rotor rotates further, the feedstock filled andpressurized chamber opens into reformer feedstock inlet line 250. Sincethe pressure in the rotor chamber is equalized with the pressure in line250, the feedstock falls down into feedstock inlet line 250. As thevalve rotor continues on its journey, it is eventually vented throughoutlet pressure vent line 289, such that when the chamber again reachesfeed hopper outlet line 296, it is depressurized and will not vent backup into feed hopper outlet line 296. After feedstock has moved throughrotary feeder valve 297 and into feedstock line 250, it feeds by gravityinto a mixing chamber or position along mixing apparatus feedstock inletline 250 where the feedstock is mixed with superheated steam (e.g. steamhaving a temperature of about 510° C. (950° F.)) from superheated steamline 550.

II. Method of producing synthesis gas. Also disclosed herein is a methodof producing synthesis gas via reforming of carbonaceous material. Inembodiments, the carbonaceous material comprises primarily biomass. Thebasic steps in the method of producing synthesis gas according to thisdisclosure are depicted in the flow diagram of FIG. 5. As indicated inFIG. 5, a method of producing synthesis gas conversion product 600comprises preparing carbonaceous feedstock at 610, preparing reformerfeed at 620 and reforming the reformer feed at 630. Preparingcarbonaceous feed material 610 comprises comminuting and/or drying asuitable carbonaceous feed material. In embodiments, the source of thecarbonaceous feedstock comprises biomass. In embodiments, thecarbonaceous feedstock comprises at least one component that is or thatis derived from lignite, coal, red cedar, southern pine, hardwoods suchas oak, cedar, maple and ash, bagasse, rice hulls, rice straw, weedssuch as kennaf, sewer sludge, motor oil, oil shale, creosote, pyrolysisoil such as from tire pyrolysis plants, used railroad ties, drieddistiller grains, corn stalks and cobs, animal excrement, straw, andcombinations thereof.

Preparing carbonaceous feedstock 610. In embodiments, preparing thecarbonaceous feedstock 610 comprises sizing (comminuting) at least onecarbonaceous feedstock such that it is of a desirable size for effectivereforming. In embodiments, preparing the carbonaceous feedstockcomprises reducing the average particle size of the feedstock to lessthan about ⅝^(th) inch (15.9 mm), ½ inch (12.7 mm), or less than about3/16^(th) of an inch (4.8 mm). The carbonaceous feedstock may be sizedby any methods known in the art. In embodiments, a carbonaceous materialis sized by introducing it into one or more grinders 210, as discussedabove with reference to FIG. 4.

In embodiments, preparing the carbonaceous feed material comprisesdrying the carbonaceous feedstock to a moisture content in the range offrom about 4 weight percent to about 20 weight percent, from about 6weight percent to about 16 weight percent, or from about 12 weightpercent to about 18 weight percent. In embodiments, preparing thecarbonaceous feed material comprises drying the carbonaceous feedstockto a moisture content in the range of from about 4 weight percent toabout 20 weight percent, from about 5 weight percent to about 20 weightpercent, from about 10 weight percent to about 20 weight percent or fromabout 5 weight percent to about 18 weight percent. In embodiments,preparing the carbonaceous feedstock comprises drying the carbonaceousfeedstock to a moisture content of less than about 25, 20, 15, 10 or 9weight percent. The carbonaceous feedstock may be dried by any methodsknown in the art. In embodiments, a carbonaceous feedstock is dried byintroducing it into one or more dryers 260, as discussed above withreference to FIG. 4. In embodiments, ground carbonaceous materialexiting grinder 210 is introduced into a grinder discharge cyclone 220.Within grinder discharge cyclone 220, a stream of larger sized particlesis separated via grinder discharge cyclone outlet line 225 from a streamof smaller sized particles in grinder discharge fines outlet line 222. Agrinder discharge blower 230 may introduce the smaller particlesseparated in grinder discharge cyclone 220 into one or more dryerbaghouse(s) 240. The larger particles exiting grinder discharge cyclone220 via grinder discharge cyclone outlet line 225 are introduced intodryer 260.

In embodiments, air supplied via air supply fan 261 and line 262 iscombined with flue gas in line 570 and introduced into dryer air heater280. The flue gas utilized here may be produced during reforming of thecarbonaceous material discussed below. Heat transfer with steamintroduced into the dryer air heater via steam inlet line 560A/560Dproduces heated air in heated air line 284 and condensate in condensateoutlet line 282. As discussed hereinabove, the steam utilized in dryerair heater 280 may be produced via heat transfer with the hot reformerprocess gas effluent and/or the ‘warm’ flue gas effluent, as discussedfurther hereinbelow.

Heated air in heated air line 284 may be divided by a heated airdistributor or divider 286 into a plurality of heated air inlet lines284A-284C. Within dryer 260, the comminuted carbonaceous material isdried to a desired moisture content, as mentioned hereinabove. Dryereffluent comprising air and fines is introduced via dryer vent line 281into dryer cyclone 265. Dried carbonaceous material exits dryer 260 viaone or more dried feed lines 294 and surge hopper 270. Air from reformerfeed hopper blower 275 may push comminuted and dried feed material fromdryer 260 and surge hopper 270 along reformer feed hopper inlet line 276into reformer feed hopper cyclone 290. Solids removed from dryer cyclone265 and dryer baghouse 240 may be introduced into reformer feed hopperinlet line 276, as indicated in FIG. 4.

Gas exiting dryer cyclone 265 may be combined in grinder dischargeblower outlet line 231 via dryer cyclone fines outlet line 266 with gasexiting grinder discharge blower 230 and gas exiting reformer feedhopper cyclone 290 via line 292 and introduced into dryer baghouse 240.Gases exiting dryer baghouse via dryer baghouse fines outlet line 244may pass via dryer exhaust fan 241 and line 247 to dryer stack 246.

Dried carbonaceous materials exit reformer feed hopper cyclone 290 andenter reformer feed hopper 295. Carbonaceous material from reformer feedhopper 295 is introduced via mixing vessel rotary feeder 297 andfeedstock line 250 into one or more mixing vessels of mixing apparatus300.

Preparing reformer feed 620. As discussed above, producing synthesis gasvia reforming of carbonaceous material 600 further comprises preparingreformer feed 620. A suitable reformer feed may be formed viacombination of superheated steam and comminuted and dried carbonaceousmaterial via any methods known in the art. In embodiments, spentcatalyst comprising spent catalyst and associated synthesis gasconversion product is combined with the carbonaceous material prior toor along with combination with superheated steam. In embodiments,preparing reformer feed comprises introducing the comminuted and driedcarbonaceous feed material and superheated steam into one or more mixingvessels as described hereinabove.

With reference to FIG. 2, preparing reformer feed material can compriseintroducing comminuted and dried feed material via lines 250, 250A and250B into mixing apparatus 300A. Spent catalyst/conversion product froma catalytic synthesis gas conversion process may be combined with thecarbonaceous material via line 755. In alternative embodiments, spentcatalyst/conversion product is introduced directly into the mixingvessel(s). Superheated steam from steam superheater 501B is introducedvia superheated steam lines 550, 550A and 550B into mixers 310A and310B, respectively.

With reference to FIG. 3, preparing reformer feed 620 can compriseintroducing comminuted and dried feed material via feedstock inlet line250 into mixing apparatus 300B. Superheated steam from steam superheater501B′ is introduced via superheated steam line 550 into mixer 310C.

As mentioned hereinabove, within the mixing apparatus, superheated steamand carbonaceous material are combined to provide a reformer feedmixture comprising from about 0.14 kilograms (0.3 pounds) to about 0.32kilograms (0.7 pounds), from about 0.14 kg (0.3 pounds) to about 0.23 kg(0.5 pounds) or from about 0.14 kg (0.3 pounds) to about 0.18 kg (0.4pounds) of steam per pound of ‘dry’ feedstock comprising from about 4%to about 20% moisture by weight, from about 9% to about 18% moisture orfrom about 10% to about 20% moisture, to provide the reformer feedmixture that is introduced into the coiled tubes of the reformer. Inembodiments, the reformer feed comprises from about 0.01 wt % to about20 wt %, from about 0.05 wt % to about 10 wt %, or from 1 wt % to about5 wt % weight percent spent catalyst/product (e.g. cat/wax). Thereformer feed may have a temperature in the range of from about 150° F.(66° C.) to about 1000° F. (538° C.), from about 200° F. (93° C.) toabout 750° F. (399° C.), or from about 300° F. (149° C.) to about 400°F. (204° C.). In embodiments, the reformer feed has a pressure of atleast or about in the range of from about 34.5 kPa (5 psig) to about 275kPa (40 psig).

The superheated steam utilized in the reformer feed mixers may beproduced by heat exchange with the reformer flue gas effluent and/or thereformer process gas effluent. With reference to FIG. 2, BFW may beintroduced via BFW inlet line(s) 580 into reformer effluent and reformerflue gas steam generator 501A. Within reformer effluent and reformerflue gas steam generator 501A, heat transfer between the hot gas (warm′reformer flue gas passing through steam superheater 501B and ‘hot’reformer process gas effluent) and the BFW may produce steam (in steamoutlet line 560) having a temperature in the range of from about 300° F.(148.9° C.) to about 500° F. (260° C.), from about 350° F. (176.7° C.)to about 500° F. (260° C.) or from about 350° F. (176.7° C.) to about500° F. (260° C.) and a pressure in the range of from about 200 psig(1379 kPa) to about 300 psig (2068.4 kPa), from about 250 psig (1723.7kPa) to about 300 psig (2068.4 kPa), or from about 275 psig (1896.1 kPa)to about 300 psig (2068.4 kPa). Steam exiting reformer effluent andreformer flue gas steam generator 501A via steam generator steam outletline 560 may be divided, with a portion entering steam superheater 501Bvia line 560B and another portion exported via line 560A. Within steamsuperheater 501B, heat transfer between ‘hot’ reformer flue gas andsteam produces superheated steam having a temperature in the range offrom about 400° F. (204.4° C.) to about 1000° F. (537.8° C.), from about600° F. (315.6° C.) to about 950° F. (510° C.) or from about 400° F.(204.4° C.) to about 900° F. (482.2° C.) and/or a pressure in the rangeof from about 150 psig (1034.2 kPa) to about 400 psig (2757.9 kPa), fromabout 200 psig (1379 kPa) to about 375 psig (2585.5 kPa) or from about250 psig (1723.7 kPa) to about 350 psig (2413.2 kPa). The superheatedsteam exiting steam superheater 501B is introduced into reformer feedmixing vessels 310A/310B via lines 550 and 550A/550B.

With reference to FIG. 3, BFW may be introduced via BFW inlet line 580into reformer effluent steam generator 501A′. Within reformer effluentsteam generator 501A′, heat transfer between the hot process gaseffluent and the BFW may produce steam. Steam exiting reformer effluentsteam generator 501A′ via line 580A may be introduced into flue gassteam generator 501A″. Within flue gas steam generator 501A″, heattransfer between ‘warm’ reformer flue gas and steam produces saturatedsteam (exiting via steam generator steam outlet line 560) having atemperature in the range of from about 300° F. (148.9° C.) to about 500°F. (260° C.), from about 350° F. (176.7° C.) to about 500° F. (260° C.)or from about 350° F. (176.7° C.) to about 500° F. (260° C.) and apressure in the range of from about 200 psig (1379 kPa) to about 300psig (2068.4 kPa), from about 250 psig (1723.7 kPa) to about 300 psig(2068.4 kPa), or from about 275 psig (1896.1 kPa) to about 300 psig(2068.4 kPa).

Reformer flue gas exiting the reformer via reformer flue gas outlet line470 passes through steam superheater 501B′, wherein the temperature ofthe ‘hot’ flue gas is reduced to a temperature in the range of fromabout 530° F. (276.7° C.) to about 1500° F. (815.6° C.), from about 530°F. (276.7° C.) to about 1200° F. (648.9° C.) or about 530° F. (276.7°C.) and/or a pressure in the range of from about −20 inches H₂O to 0inch H₂O; from about −15 inch H₂O to about −5 inch H₂O; or from about−10 inches H₂O to about −5 inches H₂O and superheated steam is produced.The superheated steam may have a temperature in the range of from about400° F. (204.4° C.) to about 1000° F. (537.8° C.), from about 600° F.(315.6° C.) to about 950° F. (510° C.) or from about 400° F. (204.4° C.)to about 900° F. (482.2° C.) and/or a pressure in the range of fromabout 150 psig (1034.2 kPa) to about 400 psig (2757.9 kPa), from about200 psig (1379 kPa) to about 375 psig (2585.5 kPa) or from about 250psig (1723.7 kPa) to about 350 psig (2413.2 kPa). The superheated steamexiting steam superheater 501B′ is introduced into reformer feed mixingvessel 310C via line 550.

Reforming reformer feed 630. As discussed above, producing synthesis gasvia reforming of carbonaceous material 600 further comprises reformingreformer feed at 630. In embodiments, reforming the reformer feed 630comprises converting the reformer feed into synthesis gas viaintroduction into a reformer as described above. Reforming of thesynthesis gas will now be described with reference to FIGS. 2 and 3.Reformer feed is introduced into the reformer via one or more reformerfeed inlet lines 350. In embodiments, a distributor 412 distributes thereformer feed evenly among a plurality of coiled tubes 410. Within thecoiled tubes, reforming of the carbonaceous feedstock produces synthesisgas. In embodiments, the temperature of the reformer (e.g. reformereffluent) is maintained in the range of up to or about 926° C. (1700°F.), 982° C. (1800° F.), 1038° C. (1900° F.), 1093° C. (2000° F.), 1149°C. (2100° F.). In embodiments, the pressure of the reformer ismaintained in the range of from about 0 psig (0 kPa) to about 100 psig(689.5 kPa), from about 2 psig (13.8 kPa) to about 60 psig (413.7 kPa)or from about 5 psig (34.5 kPa) to about 50 psig (344.7 kPa). Inembodiments, the reformer pressure is maintained at a pressure of equalto or greater than about 2 psig (13.8 kPa), about 5 psig (34.5 kPa), orabout 50 psig (344.7 kPa).

The heat needed to maintain the desired reformer temperature is providedto the endothermic reforming process by the combustion of fuel in one ormore burners 404. Air for the combustion may be heated in air preheater413 prior to burning with the fuel in burners 404. The fuel combusted inthe burner(s) 404 may be selected from tailgas (e.g. Fischer-Tropschtailgas), synthesis gas, methane (e.g. natural gas), and combinationsthereof. Desirably, at least a portion of the fuel combusted in at leastone of the burner(s) 404 comprises tailgas recycled from a synthesis gasconversion process. At least one of the burner(s) 404 may be speciallydesigned for the combustion of tailgas or for the combustion of tailgasin combination with another gas, for example in combination with a asselected from synthesis gas and methane (e.g. natural gas). Inembodiments, recycle tailgas in line(s) 770 is introduced into one ormore burner(s) 404 by introduction into one or more of the fuel lines406 or via another fuel inlet line(s).

The synthesis gas produced via this disclosure can be utilized for theproduction of a variety of products, such as, but not limited to, liquidFischer-Tropsch hydrocarbons, alcohols and other oxidized compounds. Asmentioned hereinabove, for any given feedstock, a desired composition ofthe resulting reformer product synthesis gas (i.e. the proportions ofhydrogen, carbon dioxide, carbon monoxide and methane; the molar ratioof hydrogen to carbon monoxide) can be provided by adjusting thecomposition of the dried feedstock (i.e. the components and/or themoisture content therein), the contact time in the reformer, thetemperature at the reformer outlet, ratio of steam to carbonaceousmaterial in the reformer feedstock, the reformer pressure, or anycombination of two or more thereof to provide a suitable synthesis gasfor a desired downstream application.

In embodiments, the synthesis gas is to be utilized downstream for theproduction of liquid hydrocarbons via Fischer-Tropsch conversion. Inembodiments, the synthesis gas is to be utilized downstream for theproduction of liquid hydrocarbons via Fischer-Tropsch conversion with aniron-based catalyst. In such embodiments, the system may be operatedwith a reformer exit temperature in the range of from about 898° C.(1650° F.) to about 926° C. (1700° F.) and a residence or contact timethat is in the range of from about 0.3 seconds to about 2.0 seconds inthe reformer. The contact or residence time can be calculated bydividing the internal volume of the reformer by the flow rate of theprocess gas exiting the reformer.

In embodiments, the reformer is configured to provide temperature,pressure and residence time conditions suitable to provide a process gascomprising synthesis gas having a desired molar ratio of H₂ to CO. Inembodiments, the reformer is configured to provide a synthesis gashaving a H₂:CO molar ratio in the range of from about 0.7:1 to about2:1, from about 0.7:1 to about 1.5:1 or about 1:1. In embodiments, thereformer is configured to provide a residence time within the reformerin the range of from about 0.3 s to about 3 s, from about 0.3 s to about2 s, from about 0.3 s to about 1 s, or from about 0.4 s to about 0.6 s.

While the preferred embodiments of the invention have been shown anddescribed, modifications thereof can be made by one skilled in the artwithout departing from the spirit and teachings of the invention. Theembodiments described and the examples provided herein are exemplaryonly, and are not intended to be limiting. Many variations andmodifications of the invention disclosed herein are possible and arewithin the scope of the invention. Accordingly, the scope of protectionis not limited by the description set out above, but is only limited bythe claims which follow, that scope including all equivalents of thesubject matter of the claims.

The discussion of a reference is not an admission that it is prior artto the present invention, especially any reference that may have apublication date after the priority date of this application. Thedisclosures of all patents, patent applications, and publications citedherein are hereby incorporated herein by reference in their entirety, tothe extent that they provide exemplary, procedural, or other detailssupplementary to those set forth herein.

What is claimed is:
 1. A method of producing synthesis gas, the methodcomprising: mixing a carbonaceous feed comprising at least onecarbonaceous material with superheated steam to produce a reformerfeedstock; and reforming the reformer feedstock to produce a firstsynthesis gas comprising hydrogen, and carbon monoxide by introducingthe reformer feedstock into a plurality of coiled tubes within areformer at a reformer temperature and a reformer pressure at which atleast a portion of the reformer feedstock is converted to synthesis gas;wherein the carbonaceous feed further comprises a mixture of spentcatalyst and liquid Fischer-Tropsch hydrocarbons produced as a byproductof downstream conversion of the synthesis gas to Fischer-Tropschhydrocarbons.
 2. The method of claim 1 wherein the reformer feedstockcomprises less than or equal to about 1 lb of superheated steam perpound of carbonaceous material.
 3. The method of claim 1 wherein thecarbonaceous feed comprises primarily biomass.
 4. The method of claim 3wherein each of the plurality of coiled tubes has a height in the rangeof from about 40 feet to about 100 feet and a coil length that is atleast four times the vertical height.
 5. The method of claim 4 whereineach of the plurality of coiled tubes has a coil length in the range offrom about 400 feet to about 900 feet.
 6. The method of claim 3 furthercomprising maintaining the reformer temperature via combustion of afuel.
 7. The method of claim 6 wherein the fuel comprises at least onecomponent selected from the group consisting of methane, synthesis gas,Fischer-Tropsch tailgas and combinations thereof.
 8. The method of claim3 further comprising maintaining a reformer temperature of at least1700° F.
 9. The method of claim 3 further comprising maintaining areformer pressure of at least 45 psig.
 10. The method of claim 1 furthercomprising preparing the carbonaceous feed by subjecting at least onecarbonaceous material to comminution, drying or both.
 11. The method ofclaim 10 wherein preparing the carbonaceous feed comprises grinding andsizing at least one carbonaceous material to provide at least onecarbonaceous material having an average particle size of less than about3/16^(th) inch.
 12. The method of claim 10 wherein preparing thecarbonaceous feed comprises drying at least one carbonaceous material toprovide at least one carbonaceous material having a moisture content ofless than about 20 weight percent.
 13. The method of claim 10 whereinpreparing the carbonaceous feed comprises combining at least onecarbonaceous material with a spent catalyst stream comprising spentcatalyst and at least one combustible product of synthesis gasconversion.
 14. The method of claim 13 wherein the at least one productof synthesis gas conversion comprises liquid Fischer-Tropschhydrocarbons.